Volkswagen Workshop Service and Repair Manuals > Polo Mk4 > Clutch and gearbox | 5-speed manual gearbox 02R | Gearbox,mechanics,gears,shafts,internal operation

Input shaft - adjust

(Determining input shaft adjustment shim)

Special tools and workshop equipment required

t	Clock mounting -VW 387-

t	Final measurement plate -VW 385/17-

t	Pressure disc -VW 510-

t	Pressure disc -VW 447 i-

t	Pressure pin -VW 407-

t	5 - 50 Nm Torquemeter -VAG 1331-

t	Dial gauge

It is only necessary to readjust the input shaft when the following components are renewed:

t	Gearbox housing

t	Clutch housing

t	Input shaft

t	4^th gear wheel

or the

t	Taper roller bearing

Adjustment overview → Chapter

–	Press taper roller bearing outer race, without shim, into gearbox housing onto stop.

–	Install input shaft in clutch housing and assemble gearbox housing. Tighten hexagon bolts with 25Nm + 90°.

–	Fit measuring appliance and D.T.I. in clutch housing (large taper roller bearing in gearbox housing).

–	Before taking any measurements, rotate input shaft to allow bearings to settle. Preload dial gauge to 1 mm and set to “0”.

Note

This preparation is to be repeated for each subsequent measurement, otherwise the gauge will not return to the starting position.

–	Press input shaft in direction of D.T.I. -arrow-.

–	Read off and note clearance indicated on D.T.I. (example 1.21).

Note

D.T.I. does not return to original position

–	Determine thickness of shim from table → Chapter (Example 1.175).

–	Remove input shaft and press taper roller bearing outer race out of gearbox housing using -VW 447i-.

–	Press taper roller bearing outer race together with the 1.175 shim into gearbox housing using -VW 510-

–	Assemble gearbox housing and tighten hexagon head bolts to 25 Nm and then turn 90° further

Volkswagen Workshop Service and Repair Manuals